This file was found on Thingiverse and Yeggi
Cruze (and others) coil connector lock tab
April 15, 2018
I don't expect this to be useful to a huge number of people, but if it is useful to even one person it is worthwhile sharing.
As anyone who has a 1.4L Chevrolet Cruze (or similar) and who has tried to remove the ignition coil connector to do plug service knows, the orange lock tab will break if you even look at it the wrong way.
I searched far and wide for a replacement part and could not find one.
So I measured the original and duplicated it as best I could.
Once printed in ABS and cleaned up a bit using an X-Acto knife and sandpaper I vapor polished it and it works like a charm.
Please note that in the photo it is covered in silicone grease so it appears indistinct, but it is a faithful duplicate of the original dimension-wise.
I have discovered since originally posting this that it will likely be applicable to-
Buick Encore 2013-2017
Cadillac ELR 2016
Chevrolet Cruze 2011-2016
Chevrolet Sonic 2012-16
Chevrolet Trax 2013-2016
Chevrolet Volt 2011-2015
These all share the same coil pack and connector.
It may fit other applications using "Weatherpack" connectors as well.
Folger Tech FT-5
0.1mm layer height
This is best printed in ABS, PETG or Nylon so it remains flexible.
If printed in PLA it probably would be too hard to engage the original connector tab correctly and could break again when you try to unlock it.
I chose a 0.1mm layer height and printed it very slowly (20-25 mm/sec).
I happened to use a 0.4mm nozzle, but if you can use a smaller one (such as 0.3 or 0.25) it would be even better for making the finer details.
Because this part is so small, bed adhesion really isn't much of an issue, even with ABS.
While it is still warm and pliable you may need to bend the center tab upward slightly to match the curve of the original.
I lifted it carefully with a knife blade while still stuck on the heated bed and placed the tip of a jeweler's screwdriver under it.
When it cooled it retained the shape as shown.
I do suggest printing it with the largest face against the print bed, not upright as shown in the view.
This is because it will have greater strength along the part's axis for insertion and withdrawal.
If printing it in ABS (recommended), definitely do some acetone vapor polishing on it.
This will make it smoother and also increase its strength.
I added silicone grease to it when inserting it into the original lock slider from the connector so it wouldn't jam up again and have inserted and withdrawn it several times during services since originally printing it without any problems.
You may need to make tiny adjustments to the side bumps to get it to lock smoothly.
I used an X-Acto knife for this, as mentioned.
How I Designed This
Inventor (source file included)